Krapfen, Berliner, Doughnuts, Boules de Berlin

Krapfen, Berliner, Doughnuts, Boules de Berlin

Automated production (3,200 pieces per hour)

With our production line for Krapfen and Berliner, we automate the horizontal slicing, filling, reassembling and finishing of these products. The line processes 3,200 pieces per hour and ensures a continuous production process with a consistent end result.

The Krapfen and Berliner are sliced horizontally, after which the top and bottom halves are temporarily separated. The bottom halves receive the precise amount of filling required, such as cream, whipped cream, jam or custard, before both halves are accurately reassembled.

The filled products are then gently pressed together. This gives every Krapfen and Berliner exactly the same height and distributes the filling neatly to the edges. Finally, the products are dusted with icing sugar. Other types of decoration or finishing can of course also be applied.

Calculate your savings

dosing-machine-bakery-industrial-dosing-machine

The bakery challenge

Manually or semi-automatically slicing, filling and reassembling Krapfen and Berliner at high production speeds is challenging. The process is labour-intensive and highly repetitive. Automation increases production capacity while ensuring consistent product quality. This production line combines every step into one continuous process with minimal staffing requirements.

One product, many names

Across the world, filled doughnuts in this product family are known by many regional names. Recipes, fillings and finishes may vary, but the production challenges are often similar.

Europe

  • Southern Germany and Austria: Krapfen
  • Northern and Western Germany: Berliner
  • Belgium: Boule de Berlin
  • France: Boule de Berlin
  • Portugal: Bola de Berlim
  • Spain: Berlinesa
  • Italy: Bombolone, often filled with Nutella or pastry cream
  • Poland: Pączek, traditionally made with a richer dough
  • Finland: Berliininmunkki

North and South America

  • United States: Bismarck or Jelly Donut
  • Argentina and Uruguay: Berlinesa or Bolas de Fraile, meaning ‘friars’ balls’
  • Chile: Berlín
  • Brazil: Sonho, meaning ‘dream’

Other regions

  • Israel: Sufganiyah, traditionally eaten during Hanukkah
  • Hawaii: Malasada, introduced by Portuguese immigrants

 

This production line includes the following components:

 

Feeding system and slicing machine

The Krapfen and Berliner are fed into the line via the feeding system. They are then transported in two lanes to the horizontal slicing machine. This machine has a very high slicing capacity and produces a clean, even cut, minimising waste in the form of crumbs. Other products can also be sliced if required, even when frozen.

Continuous depositing

Two depositing units positioned alongside the line apply the required amount of filling to the bottom halves. The deposit volume is continuously adjustable and can be tailored to the product. Thanks to the travelling depositing heads, the cream is applied while the products remain in motion. This maintains a continuous product flow and supports a high production capacity.

Fly-over

After slicing, the top and bottom halves are separated. The fly-over transports the top halves over the depositing units, while the bottom halves continue along the lower conveyor.

Depositing units

During transport, the bottom halves receive the required filling. Two variably adjustable depositing units ensure the correct volume and an even deposit. The depositing heads can be exchanged to achieve the required result for each specific product.

Reassembling and pressing

After depositing, the top and bottom halves are reassembled. The Krapfen and Berliner are then gently pressed together, allowing the cream to spread evenly to the edges. All settings are continuously adjustable.

Icing sugar applicator

At the end of the line, the filled Krapfen and Berliner are evenly dusted with icing sugar.

Automatic loading onto cardboard inserts or into packaging

After cutting, filling, assembling and finishing, the Krapfen, Berliners, doughnuts or boules de Berlin can be automatically placed onto cardboard inserts or directly into the packaging. The loading solution is tailored to the product size, required positioning and capacity of the production line. This ensures that the final step integrates seamlessly into the automated production process while reducing manual handling.

 

Want to know how much you could save?

Would you like to know where Rens Bakery Solutions can deliver the greatest savings in your production process? We would be happy to visit your facility, discuss the options and calculate your potential cost savings.

Calculate your savings

Request more information